Kemppi KMS 400 AS User Manual

FastMig
KMS 400 AS
Operating manual
EN
OPERATING MANUAL
English
EN
CONTENTS
1. Preface ...................................................................................................................................... 3
1.1 General ....................................................................................................................................... 3
1.2 About FastMig KMS AS product........................................................................................ 3
2. Installation ............................................................................................................................. 4
2.1 Before use .................................................................................................................................. 4
2.2 Machine introduction ........................................................................................................... 5
2.3 Positioning and location of the machine ...................................................................... 5
2.4 Connecting cables ................................................................................................................. 6
ArcFeed ............................................................................................................................. 6
2.4.2 FastMig KMS AS + ArcFeed ............................................................................................. 6
2.5 Connection to the mains supply ...................................................................................... 7
2.6 Welding and earth cables.................................................................................................... 7
2.7 Functions of AS panel ........................................................................................................... 8
2.8 Setup functions ....................................................................................................................... 9
3. Operation control switches and potentiometers ....................................... 9
3.1 Main switch I/O ....................................................................................................................... 9
3.2 Pilot lamps ................................................................................................................................. 9
3.3 Operation of cooling fan ..................................................................................................... 9
4. Basic troubleshooting .................................................................................................10
5. Maintenance ......................................................................................................................11
5.1 Daily maintenance ...............................................................................................................11
5.2 Periodic maintenance .........................................................................................................11
5.3 Service shop maintenance ...............................................................................................11
6. Operation disturbances .............................................................................................12
6.1 Operation of the overload protection ..........................................................................12
6.2 Control fuses ..........................................................................................................................12
6.3 Under- and overvoltages in the mains supply ..........................................................12
6.4 Loss of a phase in the mains supply ..............................................................................12
7. Disposal of the machine ............................................................................................12
8. Ordering numbers .........................................................................................................13
9. Technical data ...................................................................................................................14
2
FastMig KMS 400 AS
1. PREFACE
1.1 General
Congratulations on choosing the FastMig welding equipment. Used correctly, Kemppi products can signicantly increase the productivity of your welding, and provide years of economical service.
This operating manual contains important information on the use, maintenance and safety of your Kemppi product. The technical specications of the equipment can be found at the end of the manual.
Please read the manual carefully before using the equipment for the rst time. For your own safety and that of your working environment, pay particular attention to the safety instructions in the manual.
For more information on Kemppi products, contact Kemppi Oy, consult an authorised Kemppi dealer, or visit the Kemppi web site at www.kemppi.com.
The specications presented in this manual are subject to change without prior notice.
Important notes
Items in the manual that require particular attention in order to minimise damage and personal harm are indicated with the ’NOTE!’ notation. Read these sections carefully and follow their instructions.
Disclaimer
While every eort has been made to ensure that the information contained in this guide is accurate and complete, no liability can be accepted for any errors or omissions. Kemppi reserves the right to change the specication of the product described at any time without prior notice. Do not copy, record, reproduce or transmit the contents of this guide without prior permission from Kemppi.
EN
1.2 About FastMig KMS AS product
FastMig KMS 400 AS is CC (constant current) / CV (constant voltage) power source designed for demanding professional use. It is suitable for MMA and MIG welding in DC.
FastMig KMS 400 AS is compatible with MSF, MXF and ArcFeed wire feeders.
© Kemppi Oy / 1515
3
EN
2. INSTALLATION
2.1 Before use
The product is packed in specially designed transport cartons. However, before use always make sure the products have not been damaged during transportation.
Check also that you have received the components you ordered and the instruction manuals needed, as described in the Quick start guide pack. Product packaging material is recyclable.
NOTE! When moving the welding machine, always lift it from the handle, never pull it from the
welding gun or other cables.
Operating environment
This machine is suitable for both indoor and outdoor use. Always make sure that the air ow to the machine is unrestricted. The recommended operating temperature range is –20…+40°C.
Please ensure you read the safety instructions concerning operating environments supplied in this manual.
Distribution network
All regular electrical devices without special circuits generates harmonic currents into the distribution network. High rates of harmonic current may cause losses and disturbance to some equipments.
This equipment complies with IEC 61000-3-12 provided that the short-circuit power Ssc is greater than or equal to 4.7 MVA at the interface point between the user’s supply and the public supply network. It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the equipment is connected only to a supply with a short-circuit power Ssc greater than or equal to 4.7 MVA.
4
FastMig KMS 400 AS
2.2 Machine introduction
H11
S11
H12 X14
X12
F11 H11 H12 S11 X11, X13
X11
Fuse for connection for control table 6.3 A delayed Signal lamp I/O Warning lamp for thermal protection Main switch I/O Welding connection parallel
X13
X12 X14 , X15 01
2.3 Positioning and location of the machine
Place the machine on a rm, dry and level surface. Where possible, do not allow dust or other impurities to enter the machines cooling air ow. Preferably site the machine above oor level; for example on a suitable carriage unit.
Notes for positioning the machine
• The surface inclination should not exceed 15 degrees.
• Ensure the free circulation of the cooling air. There must be at least 20 cm of free space in
front of and behind the machine for cooling air to circulate.
• Protect the machine against heavy rain and direct sunshine.
NOTE! The machine should not be operated in the rain as the protection class of the machine,
IP23S, allows for outside preserving and storage only.
01
6,3A
Earth connection Connection for control cable parallel Inlet of mains cable
F11
X15
EN
NOTE! Never aim metallic grinding spray/sparks towards the equipment.
© Kemppi Oy / 1515
5
EN
2.4 Connecting cables
NOTE! Always check before use that the interconnecting cable, shielding gas hose, earth return
lead/clamp, and mains cable is in a serviceable condition. Ensure that connectors are correctly fastened. Lose connectors can impair welding performance and damage connectors.
2.4.1 Liquid cooled system: FastMig KMS AS + MSF/MXF + FastCool 10 + ArcFeed
GND
6
2.4.2 FastMig KMS AS + ArcFeed
ArcFeed
GND
FastMig KMS 400 AS
2.5 Connection to the mains supply
FastMig power sources are delivered as standard with 5 meters of mains power cable. No mains plug is tted at the Kemppi factory.
NOTE! If local country based regulations state an alternative power cable is required, the mains
cable must be replaced in conformity with the regulations. Connection and installation of the mains cable and plug, should only be carried out by a suitably qualied person.
Remove the machine cover plate to enable mounting of a mains cable. FastMig Pulse power sources can be connected to the mains supply of 400 V 3~ .
If changing the mains cable take into consideration the following:
The cable is entered into the machine through the inlet ring on the rear panel of the machine and fastened with a cable clamp. The phase conductors of the cable are coupled to connectors L1, L2 and L3. The earth protection coloured green-yellow is coupled to the marked connector
. If you are using 5-lead cable, do not connect the neutral conductor.
EN
Sizes of the mains cables and fuse ratings for the machine at 100 % duty cycle are specied in the table below:
Rated voltage Mains voltage range Fuses, slow-blow Connection cable *) mm²
KMS 300 400 V 3~ 360 V – 440 V 20 A 4 x 6.0 S KMS 400 400 V 3~ 360 V – 440 V 25 A 4 x 6.0 S KMS 500 400 V 3~ 360 V – 440 V 35 A 4 x 6.0 S
*) In cables of S type there is a protective grounding conductor coloured green-yellow.
2.6 Welding and earth cables
Recommended copper cables with cross-sectional area are as follows: FastMig KMS 400 AS 70 – 90 mm² In enclosed table are shown typical load capacities of rubber insulated copper cables, when
ambient temperature is 25 °C and lead temperature is 85 °C.
Cable Duty cycle ED Voltage loss / 10 m
100 % 60 % 30 % 50 mm² 285 A 370 A 520 A 0,35 V / 100 A 70 mm² 355 A 460 A 650 A 0,25 V / 100 A 95 mm² 430 A 560 A 790 A 0,18 V / 100 A
Do not overload welding cables due to voltage losses and heating. Fasten the earth clamp of the return current cable carefully, preferably direct onto the piece to
be welded. The contact surface of the earth clamp should always be as large as possible. Clean the fastening surface from paint and rust.
© Kemppi Oy / 1515
7
EN
2.7 Functions of AS panel
ON/OFF button
MIG dynamics / MMA Arc Force adjustment
• When CV is selected, parameter name ’dYn’ and the adjustable value between -9 ... 9 are shown
• When CC/MMA is selected, parameter name ’Arc’ and the adjustable value between -9 ... 9 are
shown
• In MXF mode the dynamics cannot be adjusted with the AS panel and ’--- ---’ is shown. In this case the adjustment is done through the wire feeder panel
CC/MMA = Constant current mode. Selection with a long press. Selected when operated with ArcFeed with CC-mode or MMA welding
MXF mode = Use with MSF or MXF feeders CV mode = Constant Voltage. Selected when operating with ArcFeed CV-mode
Remote selection
• In CC/MMA mode the current can be adjusted with the remote
• In CV mode the voltage can be adjusted with the remote
MIG/MAG welding
FastMig KMS AS is designed for MIG/MAG welding with either the Kemppi ArcFeed voltage sensing wire feed unit, or FastMig series MSF and MXF wire feeding units. When using MSF or MXF wire feed units, connect the unit as described in picture on page 6, and select the MXF mode from the AS panel. For further information see MSF or MXF manuals.
When you use the ArcFeed voltage sensing wire feed unit, you must select either CC or CV (Constant Current or Constant Voltage) mode from the AS control panel. Ensure that the ArcFeed control panel has been set to correspond with the power source control panel. For example if power source is set to CC mode, the ArcFeed should also be set to CC mode. In CV mode FastMig AS has two welding programs for ArcFeed welding: one for self shielding ller wires and the other for standard cored and solid ller wires. The welding program can be changed in SETUP function.
It is possible to connect MSF or MXF and ArcFeed feeders to FastMig KMS AS power source simultaneously. For example, this can be an ecient combination when using Kemppi
8
FastMig KMS 400 AS
WiseRoot process for root pass welding and then completing hot pass and ller runs with ArcFeed system using self-shielded ller wire.
MMA welding
FastMig KMS AS is also suitable for MMA welding with basic or rutile electrodes. MMA welding works with CC (Constant current) mode set from the AS power source panel.
NOTE! In CC/MMA mode FastMig KMS AS has two welding programs: one for ArcFeed CC welding
and the other for MMA welding. The desired welding program can be chosen from the KMS AS ‘SETUP’ function.
TIG welding
By connecting MasterTig LT 250 to FastMig M with AS panel, TIG welding can be done. You must select either CC or CV (Constant Current or Constant Voltage) mode from the AS control panel.
2.8 Setup functions
With a long press of the SETUP button you can move to the Setup menu
Start Power Device address
Welding program CC/MMA Welding program CV Restore factory settings
Remote control
StA -9 ... +9 0 Strength of start pulse Add 3 or 6 6 System bus address. Each device in same system
must have dierent address. Pro Stl, FEE StI is for MMA welding FEE is for ArcFeed Pro Std, InS InS is for innershield wires Std for other wires FAC OFF, PAn, ALL OFF Restores factory settings, when PAn or ALL is
selected rc OFF, on OFF Manual control / remote control unit selection
3. OPERATION CONTROL SWITCHES AND POTENTIOMETERS
3.1 Main switch I/O
When you turn the switch into I-position, pilot lamp H11 on the front face is illuminated and the machine is ready for use.
NOTE! Always turn the machine on and o with the mains switch, never use the mains plugs as a
switch.
3.2 Pilot lamps
The pilot lamps of the machine report the electric operation: The green pilot lamp H11 when lit indicates that the machine is on and ready for use and it is
connected to the mains supply with the main switch in the I-position. H12 indicates when lit that the thermal protection of the machine has been activated due to
over heating. The cooling fan will continue to run and cool the machine down and when the lamp is o the machine is ready to weld.
EN
3.3 Operation of cooling fan
In FastMig KMS 400 AS power source there is two simultaneously operating fans.
• The fan is started for a moment when main switch is placed into position I.
• The fan will start during welding as the machine heats up and it will run for 1 to 10
minutes after the welding has stopped.
© Kemppi Oy / 1515
9
EN
4. BASIC TROUBLESHOOTING
NOTE! The problems listed and the possible causes are not denitive, but serve to suggest some
standard and typical situations that may present during normal environmental use when using the MIG/MAG process with FastMig.
Problem Check the following
Machine won’t work? • Check mains plug is connected
• Check mains power distribution is switched on
• Check the mains fuse and or circuit breaker
• Check power source 0/I switch is ON
• Check interconnection cable set and connectors between the power source and
wire feed unit are correctly fastened. See the manual schematic
• Check earth return lead is connected
• Check function panels are switched on – Orange buttons top left, long press.
Dirty, poor quality weld? • Check shielding gas supply
• Check and set gas ow rate
• Check gas type for application
• Check gun/electrode polarity. Example: Fe solid ller wire: Earth return should be
connected to the – pole, wire feed unit to the + pole connector
• Check correct welding curve selected
• Check correct Channel (job) number selected on PF65 function panel
• Check power supply – Phase down?
Variable welding performance? • Check wire feed mechanism is correctly adjusted
• Check correct drive rolls are tted
• Check wire spool overrun tension is correctly adjusted
• Check gun liner is not blocked. Replace if necessary
• Check correct gun liner is tted for the ller wire size and type
• Check contact tip for size, type and wear
• Check gun is not over heating in application
• Check cable connections and earth return clamp
• Check welding parameter settings.
Filler wire won’t feed? • Check wire feed mechanism. Pressure arms are closed? Close and adjust
• Check welding gun switch function.
• Check euro gun collar is correctly fastened to euro block
• Check gun liner is not blocked
• Check contact tip, size, type, wear
• Check and try alternative gun.
High spatter volume? • Check welding parameter values
• Check inductance/Dynamics values
• •Checkcablecompensationvalueiflongcablesaretted
• Check gas type and ow
• Check welding polarity – cable connections
• Check ller material selection
• Check correct welding curve selected
• Check correct Channel (job) number selection
• Check ller wire delivery system
• Check power supply – 3 x phase present?
NOTE! Many of these checks may be carried out by the operator. However certain checks relating to
mains power must be completed by an authorised trained electrician.
10
FastMig KMS 400 AS
5. MAINTENANCE
When considering and planning routine maintenance, please consider the frequency of machine use and the working environment.
Correct operation of the machine and regular maintenance will help you avoid unnecessary downtime and equipment failure.
NOTE! Disconnect the machine from the mains before handling the electrical cables.
5.1 Daily maintenance
• Check the overall condition of the welding gun. Remove welding spatter from the contact tip and clean the gas nozzle. Replace worn or damaged parts. Only use original Kemppi spare parts.
• Check the condition and connection of the welding circuit components: welding gun, earth return cable and clamp, sockets and connectors.
• Check the condition of the feed rolls, needle bearings and shafts. Clean and lubricate bearings and shafts with a small quantity of light machine oil if necessary. Assemble, adjust and test function.
5.2 Periodic maintenance
NOTE! Periodic maintenance should only be carried out by a suitably qualied person. Disconnect
the plug of the machine from the mains socket and wait approx.2 minutes (capacitor charge) before removing the cover plate.
Check at least every half year:
• Electric connectors of the machine – clean any oxidized parts and tighten loose connections.
NOTE! You must know the correct tension torques values before starting the reparation of the loose
joints.
Clean the inner parts of the machine from dust and dirt e.g. with a soft brush and vacuum cleaner. Also clean the ventilation net behind the front grill.
Do not use compressed air, there is a risk that the dirt will compact even more tightly into gaps of cooling proles.
Do not use pressure washing devices. Only an authorized trained electrician should carry out repairs to Kemppi machines.
5.3 Service shop maintenance
Kemppi Service Workshops complete maintenance according to their Kemppi service agreement.
The major points in the maintenance procedure are listed as follows:
• Cleaning of the machine
• Checking and maintenance of the welding tools
• Checking of connectors, switches and potentiometers
• Checking of electric connections
• Checking of mains cable and plug
• Damaged parts or parts in bad condition are replaced by new ones
• Maintenance testing.
• Operation and performance values of the machine are checked, and when necessary
adjusted by means of software and test equipment.
EN
© Kemppi Oy / 1515
11
EN
6. OPERATION DISTURBANCES
Should you experience a malfunction from your machine, please consult the basic troubleshooting text above rst, and complete some basic checks. If the machine malfunction cannot be corrected with these measures, contact your KEMPPI maintenance service workshop.
6.1 Operation of the overload protection
Yellow thermal protection lamp is lit when the thermostat is operating due to loading beyond the stated duty cycle.
The thermostat will operate, if machine is continuously loaded over rated values or cooling air circulation is blocked.
Internal fans will cool the machine, and when the pilot lamp is not lit the machine is automatically ready for welding.
6.2 Control fuses
Fuse, 6.3 A delayed, on the rear wall of machine provides protection for auxiliary devices.
NOTE! Use same type and rating of fuse which is marked beside the fuse adapter. Damage caused
by a wrong type fuse is not covered by the guarantee.
6.3 Under- and overvoltages in the mains supply
Primary circuits of the machine are protected against sudden, transient overvoltages. The machine is designed to withstand 3 x 440 V voltage continuously (see technical data). Ensure that voltage is kept within this admissible limit, especially when the mains supply is provided by a combustion engine generator. If the mains has under voltage (under approx. 300 V) or overvoltage (over approx. 480 V) machine control stops operation automatically.
6.4 Loss of a phase in the mains supply
Loss of a main power phase causes noticeably poor welding properties. In some cases the machine won't start at all. Loss of a phase can be due to following:
• Blowing of mains supply fuse
• Defective mains cable
• Bad connection of mains connection cable on terminal block or plug of machine.
7. DISPOSAL OF THE MACHINE
Do not dispose of electrical equipment with normal waste! In observance of European Directive 2002/96/EC on waste electrical and electronic
equipment, and its implementation in accordance with national law, electrical equipment that has reached the end of its life must be collected separately and taken to an appropriate environmentally responsible recycling facility.
The owner of the equipment is obliged to deliver a decommissioned unit to a regional collection centre, per the instructions of local authorities or a Kemppi representative. By applying this European Directive you will improve the environment and human health.
12
FastMig KMS 400 AS
8. ORDERING NUMBERS
FastMig KMS 400 AS Wire feeders ArcFeed 200 ArcFeed 300 ArcFeed 300P MXF 65 MXF 67 MXF 63 MXF 65 MXF 67 MXF 63 Panels for MSF and MXF feeders SF 51 SF 52W SF 53W SF 54 Accessories Return current cable Return current cable Cable for MMA welding Cable for MMA welding Remote controlled interconnecting cable Cooling unit Fastcool 10 Transport unit PM 500 Gun holder GH 30
6054001
6120200 6120300 6120310 6152100EL 6152200EL 6152300EL 6152100 6152200 6152300
6085100 6085200W 6085300W 6085400
5 m, 50 mm² 6184511 5 m, 70 mm² 6184711 5 m, 50 mm² 6184501 5 m, 70 mm² 6184701 10 m 6185481
6068100 6185291 6256030
EN
© Kemppi Oy / 1515
13
EN
9. TECHNICAL DATA
FastMig KMS 400 AS Connection voltage
3~, 50/60 Hz 400 V -15 %...+20 %
Rated power
60 ED ­80 % ED 19.5 kVA 100 % ED 18.5 kVA
Connection cable/fuse delayed
H07RN-F 4G6 (5 m) Fuse (delayed) 35 A
Load capacity 40 °C
60 % ED ­80 % ED 400 A 100 % ED 380 A
Welding current and voltage range
MMA 10 A ... 400 A MIG 10 V ... 39 V
Max. welding voltage Open circuit voltage Open circuit power Efficiency at max. current Power factor at max. current Operating temperature range Storage temperature range Degree of protection EMC class Minimun short circuit power Ssc of supply network* External dimensions (LxWxH) Weight Voltage supply for auxiliary devices X14, X15 Voltage supply for cooling unit
46 V 50 V 25 W 87 %
0.9
-20 ... +40 ºC
-40 ... +60 ºC IP23S A
4.7 MVA 590x230x430 mm 35 kg 50 V DC fuse 6.3 A delayed 1~ 400 V AC and 24 V DC
14
* See paragraph 3.1.
FastMig KMS 400 AS
KEMPPI OY
Kempinkatu 1 PL 13 FIN-15801 LAHTI FINLAND Tel +358 3 899 11 Telefax +358 3 899 428 export@kemppi.com www.kemppi.com
Kotimaan myynti:
Tel +358 3 899 11 Telefax +358 3 734 8398 myynti.@kemppi.com
KEMPPI SVERIGE AB
Box 717 S-194 27 UPPLANDS VÄSBY SVERIGE Tel +46 8 590 783 00 Telefax +46 8 590 823 94 sales.se@kemppi.com
KEMPPI NORGE A/S
Postboks 2151, Postterminalen N-3103 TØNSBERG NORGE Tel +47 33 346000 Telefax +47 33 346010 sales.no@kemppi.com
KEMPPI DANMARK A/S
Literbuen 11 DK-2740 SKOVLUNDE DANMARK Tel +45 4494 1677 Telefax +45 4494 1536 sales.dk@kemppi.com
KEMPPI BENELUX B.V.
NL-4801 EA BREDA NEDERLAND Tel +31 765717750 Telefax +31 765716345 sales.nl@kemppi.com
KEMPPI (UK) LTD
Martti Kemppi Building Fraser Road Priory Business Park BEDFORD, MK44 3WH UNITED KINGDOM Tel +44 (0)845 6444201
Telefax +44 (0)845 6444202 sales.uk@kemppi.com
KEMPPI FRANCE S.A.S.
65 Avenue de la Couronne des Prés 78681 EPONE CEDEX FRANCE Tel +33 1 30 90 04 40 Telefax +33 1 30 90 04 45 sales.fr@kemppi.com
KEMPPI GMBH
Perchstetten 10 D-35428 LANGGÖNS DEUTSCHLAND Tel +49 6 403 7792 0 Telefax +49 6 403 779 79 74 sales.de@kemppi.com
KEMPPI SPÓŁKA Z O.O.
Ul. Borzymowska 32 03-565 WARSZAWA POLAND Tel +48 22 7816162 Telefax +48 22 7816505 info.pl@kemppi.com
KEMPPI AUSTRALIA PTY LTD
13 Cullen Place P.O. Box 5256, Greystanes NSW 2145 SMITHFIELD NSW 2164 AUSTRALIA Tel. +61 2 9605 9500 Telefax +61 2 9605 5999 info.au@kemppi.com
OOO KEMPPI
Polkovaya str. 1, Building 6 127018 MOSCOW RUSSIA Tel +7 495 240 84 03 Telefax +7 495 240 84 07 info.ru@kemppi.com
ООО КЕМППИ
ул. Полковая 1, строение 6 127018 Москва Tel +7 495 240 84 03 Telefax +7 495 240 84 07 info.ru@kemppi.com
KEMPPI, TRADING (BEIJING) COMPANY LTD
Unit 105, 1/F, Building #1, No. 26 Xihuan South Rd., Beijing Economic-Technological Development Area (BDA), 100176 BEIJING CHINA Tel +86-10-6787 6064 +86-10-6787 1282 Telefax +86-10-6787 5259 sales.cn@kemppi.com
肯倍贸易(北京)有限公司 中国北京经济技术开发区 西环南路261号楼1105室(100176) 电话: +86-10-6787 6064/1282 传真: +86-10-6787 5259
sales.cn@kemppi.com
KEMPPI INDIA PVT LTD
LAKSHMI TOWERS New No. 2/770, First Main Road, Kazura Garden, Neelankarai, CHENNAI - 600 041 TAMIL NADU Tel +91-44-4567 1200 Telefax +91-44-4567 1234 sales.india@kemppi.com
KEMPPI WELDING SOLUTIONS SDN BHD
No 12A, Jalan TP5A, Taman Perindustrian UEP, 47600 Subang Jaya, SELANGOR, MALAYSIA Tel +60 3 80207035 Telefax +60 3 80207835 sales.malaysia@kemppi.com
www.kemppi.com
1905320
1515
Loading...